My Turbocharged M800 MPFi

. This is a discussion on My Turbocharged M800 MPFi within Accessories & Modifications. Part of The Mech's Garage category; Yes, Alternator was relocated to a/c location (towards firewall). This was done to make space for the turbo setup and ...

Could you post a snap of the engine bay and the turbo plumbing? Also, a snap of the boost gauge please. What engine oil are you using? How hot does the engine run on a highway at sustained 'turbo' speeds? How did you map the ECU? Are you running OBD?

Now thats a massive DIY I tell you. Especially getting the power/torque outcome right - how did you manage that - you mentioned 2.5k rpm for turbo to kick - did i read that right ? thats a bit too high?
Please get a dyno test done and report results.
Also your first priority has to be brakes upgrade now!

Thanks torq118, sam, Iron rock.
Yes, it was tricky to find enough space to place the turbo.
The car runs fine on sustained highway drives, munching miles and feels very effortless on highways. I am running a Race Dynamics ECU to take care of fueling and ignition and 265cc injectors. Im not running anything on/through the OBD port. Its hard to find hardware that supports these pre-OBDII setups other than Tech-II or Tech-I.

Yes, turbo spools by around 2-2.5K rpm. I could make it spool a bit earlier by varying the cam timing but theres a price to pay - top end suffers a bit with this.

Brake upgrade - totally agree. I need to do something about it. Would love to upgrade the whole front suspension (incl - struts, rotors, caliper etc from a larger donor vehicle). But, that in iteself would be a project !! ... lol ...

I did get a chance to sit it Joeking's Turbocharged 800 while driving down from Nandi hills till the Bangalore international airport toll booth when we had 800cc meet, check the link below. Boy, wat a ride it was! I was kind of drooling. Also, the exhaust note was a music to ears. I had only heard of it when Varun mentioned me about joeking's 800 but when I experienced it i could not just believe and it was awesome.

Thanks for the much needed snaps. Mind sharing details of the installation of the rpm/turbo gauge (routing of the wiring, electrical plumbing, etc.)? Where did you source these gauges from and for how much? Also, what did this setup necessitate for the ignition timing? What engine oil are you using and how is the clutch coping up till now? How many kilometres covered after the turbo job? Does the engine run hot?

Would love to listen to a sound clip of the turbocharged triple pot motor , please post it. Also, how about sharing crude acceleration timings?

The best thing about sharing this type of info is that one person does hard work, makes mistakes, works some more, rectifies the mistakes and all that the rest have to do is just copy it and save time and money on the same mod. Classic example is Varun's thread. God know how many people have benefitted from it. Hope this thread will be the same.

Right said there Peter. What a pity no carmaker takes a cue from this readily served on a platter recipe - save R&D money, just log on and choose; and guys like us have to keep waiting for a Zen with the Esteem's enginetill the time they decide to shut the tap on the Zen and give us the Zen Estilo instead.

Tach - wired it to the ignition coil - wires taken through the wirewall.
Boost gauge - T'ed out from one of the manifold vacuum/boost lines. This line is taken through the firewall and given to the boost gauge and on-board Race Dynamics ECU MAP sensor (ensuring that both the ECU and the gauge sees the same level of boost).
I was using the same liquid filled Autometer boost gauge in my supercharged VW corrado back in the US. Pulled it out when I sold my VW. I miss that car a lot !!!

You can run boosted without ignition control ( or offsetting dizzy) on low boost setup (4-5 psi). In such setup you may have to run slightly richer to keep detonation/pinging at bay. To get better performance and reliability its better to have some form of ignition control on boost.

Im running OEM maruti clutch which does a good job till 12-14 psi. Beyond that it may be a matter of time before it gives up. For a while I was running 14-16 psi and the clutch gave up (started slipping on high boost).

My Maruti 800 has done about 21000 kms after boosting it. It hasn't given me a single problem except for a leaking turbo oil line on day 2 of the build. Had to replace the "banjo" setup and copper washer to get a good tight seal. The temp levels are comparable to stock on highways. But if you are constantly boosting like uphill etc the engine bay feels hotter than usual and the turbo/ manifold smells real hot too. Having said that the temp gauge has always stayed in its limit.

The overall reliability and the heat related stability may also lend itself to the appropriate range of AFR and ignition timing that Im running. Changes in that does impact the whole state of tune and reliability big time.

Peter - I hope people do more DIYs and enjoy their work/fruit also learning as they do things/mods.

Sam - distance between boost gauge & on board MAP sensor is about 20-25cms. It has provision (extra bung) for wideband setup. Borrowed one a few times to check and tune. Especially after each injector upgrade (175cc and 265cc injectors).

Next - collecting parts for my next build. which may take a long long time. The idea is to collect the right parts (as and when I have money to spare) and then buy the engine and prepare the block and head as per needs and swap in the internals to check for right clearances. This also gives you enough time to measure every thing/aspect for plumbing routing and also space required for making custom turbo and intake manifold/plenum design etc. And finally buy the car to plonk this setup into it.

Well, this is the idea and as always, I usually take time to collect the right parts and pre-prep the setup. Putting it all together may not be much of a problem. Hopefully.

Will post more pix later.

Last edited by joeking; 16th November 2013 at 09:48 AM.
Reason: punctuation